Pallet with collapsible frame and bag

ABSTRACT

A pallet with hinged end walls, joined by detachable cross bars, may have a similar pallet stacked thereon. When the walls are collapsed, a superimposed identical pallet will have its U-shaped feet (if made of metal) or the body of the pallet base (if the latter is made of timber) nested inside corners defined by corner stub angle posts. When the walls a erected, the stacked pallet nests within corners provided by the end wall framing. A bag (having an optional roof supported by ridge rod Q) may be supported by the walls of the pallet and stiffened by battens within sleeves in the bag.

1. FIELD OF THE INVENTION

This invention relates generally to collapsible pallets, frames and other devices designed to provide purpose made fitted bags with the structural integrity and the handling and transport efficiency necessary to perform as general purpose containers for the carriage and storage of a wide range of agricultural produce, goods, liquids and other merchandise.

DESCRIPTION OF RELATED ART

Bags are generally recognised as man's most popular and ancient form of container and in recent years bags have been enjoyed renewed usage in the form of Intermediate Bulk Containers popularly known as IBCs and also Flexible Intermediate Bulk Containers more popularly known as FIBCs.

IBCs are frequently mounted on a pallet base and some have bellows style ribbing inside a vertical frame or other supporting mechanisms.

However most IBCs are rigid and made of non-flexible material such as metal or plastic and are designed for storing liquids and viscous products.

FIBCs are a similar pallet size but are most frequently used without a pallet base and are typically lifted and handled by forklifts which engage lifting loops on the tops of the bags.

FIBCs are mostly used for the storage and transport of what are called dry and flowable products such as pellets, powders and granules, another popular use is for the transport of hard agricultural produce such as potatoes.

Typical illustrations of this type of bag usage can be seen in U.S. Pat. Nos. 6,974,783; 6,935,500, 5,884,794 and 6,932,266.

As can be seen from inspecting the above and numerous others listed under the same and similar categories all of these inventions are narrowly and specifically designed to handle what is generally called bulk product as described above as dry and flowable product in an unsupported bag format.

It will also be seen that none of these products are designed to use the bag as a multi-purpose, high utility, general purpose, transport, storage and handling system.

Other types of hard collapsible containers made from materials such as metal, mesh or ply have disadvantages including high cost, excessive weight, lack of ventilation, hard surfaces that are prone to damage fragile contents, lack of effective rain protection, security or privacy closure, become excessively hot in sunlight, are prone to water damage and are difficult to clean or restore

OBJECTS OF THE INVENTION

It is an object of the present invention to provide a comprehensive size range of collapsible bag container products to service the widest possible range of agricultural produce, goods and merchandise.

Another object of the present invention is to provide a range of collapsible bag containers that will function as a returnable packaging system in lieu of existing “hard” containers including metal, mesh, ply or timber products.

A further object of the present invention is to provide a collapsible container that will function as a returnable packaging system.

Another object of the present invention is to provide a collapsible bag container assembly that can be fitted to existing or purpose made timber pallets.

Another object of the present invention is to provide a collapsible bag container that makes the most cost efficient use of metal, timber and fabrics to produce a more cost effective container than conventional collapsible containers traditionally manufactured from sheet metal, mesh or ply materials.

Another object of the present invention is to provide a collapsible bag container that when manufactured from metal will provide four way access for the tynes of forklifts and other lifting devices in both collapsed and erected formats.

Another object of the present invention is to provide a collapsible bag container that achieves the optimum levels of safety in handling and transport operations.

A further object of the present invention is to provide a collapsible bag container that securely and safely interlocks when self stacked in the collapsed or erected format.

Yet another object of the present invention is to provide a collapsible bag container where the bag element may be rapidly installed and or removed.

Another object of the present invention is to provide a collapsible bag container where the bag element remains securely fixed when the container is inverted for discharge purposes.

Another object of the present invention is to provide a collapsible bag container that offers a range of fabrics for the bag element that may include plain, ventilated, mesh or insulated fabrics.

A further object of the present invention is to provide a collapsible bag container that provides an optional self draining fabric attachable tonneau cover/closure that will provide rain protection and afford load/content privacy and security.

Yet another object of the present invention is to provide a collapsible bag container and optional self draining attachable tonneau cover that may be manufactured from a range of fabrics including insulated fabrics.

Another object of the present invention is to provide a collapsible bag container that may be readily converted to provide mobility options.

A further object of the present invention is to provide a collapsible bag container that is readily fitted with other lifting points designed to provide a wider range of container applications and options.

Yet another object of the present invention is to provide a collapsible bag container with access options that for loading or unloading purposes allow a person to easily step inside the container.

A further object of the present invention is to provide a collapsible bag container that provides softer floor and wall options for the protection of easily damaged agricultural produce and other fragile goods and merchandise.

Another object of the present invention is to provide a collapsible bag container whose sizes and dimensions are compatible with the internal dimensions of standard shipping containers.

SUMMARY OF THE INVENTION

A new type of general purpose collapsible container is disclosed that uses modern industrial fabrics in the form of a five-sided, open top, supported bag as the containing element.

The structural properties of the container are derived from a metal or timber pallet base with hinge down end frames where the pallet base supports the bag container loads and interfaces with the tynes of forklifts or other lifting devices or racking systems.

The bags are virtually fully supported on three of their five sides by the deck of the pallet base and the hinge down end frames and thus to limit the bag bellying in the otherwise unsupported front and back sections, metal battens may be inserted in suitably located sleeves in the bag.

Bags on their own have no structural properties and so the vertical self stacking loads in the erected form are transferred down through the hinge down end frames via the hinge mechanism and the stub posts into the pallet and footing system.

Vertical self stacking loads in the collapsed format can take the form of either the footing system of the above stacked pallet or the base of a timber pallet and are transferred from on top of the folded down end frames via the hinge mechanism and the stub posts into the pallet and footing system.

To provide safe self-stacking, handling and transport, use is made of vertical angle sections in the corner stub posts and the erected hinge down end frames, positioned to provide enclosed corners that mechanically engage and interlock the footing system of top loaded pallets or the underside corners of a timber pallet which have the effect of restricting horizontal movement or accidental displacement when self-stacked.

Drop front personal access is a common requirement in deeper containers of any construction and this is provided for in this invention by a front cutaway section of the bag that is closed and concealed with an self-apron section incorporating the front drop bar that attaches to the hinge down end frames in the manner described.

When a drop front bag is used, an alternative means of holding the two front corners of the bag is needed and this is provided for with eyelets in the bag corners that are engaged by hooks attached to the front area of the hinge down end frames.

To protect against rain damage or to provide load privacy and security a top closure system is desirable on any container and this is provided for with a purpose made fabric tonneau cover that includes a skirt type overlap that is fixed front and back with a series of strap and loop belt fastenings or other belt and buckle system.

To achieve proper rain drainage and minimise ponding the tonneau cover/closure is made in the form of a shallow A-frame that drains to the front and back and where the ridge of the A-frame is provided by a detachable bar that connects to the hinge down end frames.

Because the height of the A-frame ridge is slightly less than the underside clearance of the metal pallet base, erected pallet and bag assemblies may be self stacked without interfering with the tonneau closure system.

The invention describes how when not required the cover may be stowed in a purpose made bag or cavity attached or incorporated in one of the hinge down end frames and the ridge support member will be stowed between the spaces in the pallet deck members where the gap between the ends of the deck members and the end angle members will be used to house the end downturns of the ridge support members.

This invention, similar to shipping containers may be used as a freight module without an enclosed containing element by utilising only the base and the hinge down end frames joined by the top drop or connecting bars.

In this format the invention provides for the internal space to be subdivided in a random manner with optional lateral “space bars” that attach to mesh infills of the hinge down end frames where when not required the space bars may be stowed in the spaces provided between the pallet deck sections.

A collapsible pallet frame and bag container of various sizes is provided for by a pallet base with fold down frames opposed at each end and hinge fixed to a timber or metal pallet base via stub angle posts in each corner and where in erected form the assembly forms a U-shape when viewed from the front and where the top front and back of the end frames are joined by a pair of detachable drop bars.

Open top bags with integral longitudinal sleeves top and bottom front and back are fitted inside the erected assembly by passing the detachable drop bars through the top front and back sleeves and re-attaching the drop bars to the erected hinge down end frames.

Pins horizontally attached at each end corner of the pallet base engage the bag's bottom front and back sleeves to hold the bag open and closely fitting the pallet assembly and other horizontal intermediately positioned bag sleeves provide for the insertion of other unfixed battens when additional stiffening is required.

Personal access to deeper bag assemblies is provided for by a bag with a lowered cutaway front which is closed and concealed behind a self-apron front with integral sleeve and drop bar that attaches to the hinge down end frame fixing points provided.

Collapsibility is achieved when the bag's drop bars are detached from the hinge down end frames allowing the bag with fitted support bars to fold down upon the pallet deck allowing the end frames to fold down on top of the bag in a substantially horizontal position.

Safe nesting and stacking of both collapsed and or erected assemblies is achieved by using internal corners created by the use of angle sections suitably disposed for the stub posts and vertical members of the fold down end frames that mechanically engage the footing elements or corner sections of above stacked units.

A fabric security and self draining rain and privacy closure to the bag container is provided for with a tonneau cover in a shallow A-frame format with an overhanging skirt supported by a detachable longitudinal metal ridge member where the front and back skirts are attached to the bag with “velcro” or other fastenings.

When not required the invention provides for the top closure to be stored in a purpose made bag or other enclosure attached to the outside of the hinge down frames.

The invention provides for the storage of battens, drop bars and ridge support elements in the spaces provided between the pallet deck members when not required.

The invention will generally be all metal construction but an alternative equally performing and functioning adaptation to a timber pallet base is also disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

Dwg 1 shows a variety of plan, elevation, sectional and detailed component views of the preferred embodiment in metal pallet base format.

Dwg 2 shows a variety of plan, elevation, sectional and component views of the preferred embodiment in metal pallet base format are shown where an isometric view of a bag and cover component are included. Other views illustrate the bag attached in the collapsed and erected format. Other views show the relationship of stacked units in the erected and collapsed format.

Dwg 3 show isometric views of the preferred embodiment in a metal pallet base format with bag and cover/closure attached and the relationship of other support members attached where for purposes of clarity the bag component are not shown.

Dwg 4 shows a variety of plan, elevation, sectional views of the preferred embodiment in a timber pallet base format with other views of the stacking relationship in the erected and collapsed format.

Dwg 5 shows a variety of plan, elevation, sectional and detailed component views of the preferred embodiment in timber pallet base format and the relationship of hinge and attachment systems

DETAILED DESCRIPTION OF THE DRAWINGS

Dwg 1 details the various components where 1 illustrates the fold down side/end frames, 1A illustrates metal tabs that support the drop bars 5, 1B illustrates the hole that engages pins 5A of drop bars 5, 1C indicates the captive repository corner that capture and supports U-shape feet 4 when stacked above, 1D illustrates the mesh infill of fold down side/end frames 1, 1E are hooks to engage bag eyelets 10E and support a bag in the drop front format, 2 are the angle stub posts that support the hinge down frames 1, and provide the hinge point 6, 2A are nesting cleats designed to support upper stacked pallets when one fold down end frame overlaps another as illustrated in View H, 3 is the angle section that forms the ends of the pallet base, 3A illustrates the void storage space created between the ends of pallet deck sections 7 and the vertical flange of end angle sections 3,

4 are strap metal feet with a generally vertical outer leg designed to engage repository space 1C when one pallet is stacked upon another, 5 are the square tube drop bars designed to fit into bag sleeves 10C and engage upon support tabs 1A, 5A are the internal pins designed to engage tab holes 1B, 6 are hinge pin/bolts connecting stub posts and hinge down side frames 1, 7 are pallet deck members fixed at the ends to end angle sections 3, 7A illustrates the space between deck members 7 that may be used for the stowage of other loose members such as drop bars 5, bag battens (not illustrated) or ridge support member Q, 8 are tyne bearer wear and impact pads, 9 are bag fixing pins fixed to end angles 3 and designed to engage bag sleeves 10A, 10 illustrates one form of a drop front bag incorporating sleeves 10A designed to engage bag pins 9, 10B designed to engage stiffening battens (not shown) 10C designed to engage drop bars 5, 10D illustrates one form of drop front bag where the fold down apron is used to close and open cut away area behind, 10E is an eyelet designed to hang on bag hook 1E and support the corner of the bag when in drop front format.

In DWG 3, A shows an isometric view an erect pallet frame assembly with a drop front bag attached in the open format, A1 shows a hole in the middle top of fold down end frames 1, B shows an isometric view of an erect pallet frame assembly illustrating the relationship of drop bars 5 and ridge support member Q, C shows an isometric view of an erect pallet frame and bag assembly with a optional cover in place with the centre supported by ridge member Q and secured with belts NC fixed to buckles F1, D shows an isometric view of an erect frame assembly with space dividers R attached to mesh ends 1D, and the relationship of drop bar support tabs 1C in each corner attached to fold down end frames 1.

In DWG 2, E shows an end view of an erect pallet and bag assembly, F shows a front view of an erect pallet and bag assembly with support batten in situ and illustrating the relationship of cover buckles F1, G shows an end view of a collapsed pallet frame assembly, H1 shows a front view of a collapsed pallet frame and bag assembly where in a narrower format, one side folds down upon another

providing an uneven landing surface for stacking requiring additional nesting cleats 2A, I illustrates on form of bag with a drop front, J shows an end view of erected and stacked pallet frame and bag assemblies illustrating how U-shape strap feet 4 engage inside repository/nesting corner 1C, K shows a front view of erected and stacked pallet frame and bag assemblies illustrating how U-shape strap feet 4 engage inside repository/nesting corner 1C, L shows a front collapsed and stacked view of pallet and bag assemblies where one side folds down upon another providing an uneven landing surface for stacking requiring additional nesting cleats 2A, M shows an end collapsed and stacked view of pallet frame assemblies illustrating how U-shape strap feet 4 engage inside repository/nesting corners 1C, N illustrates on form of cover/closure showing cutout ends NA to accommodate drop bars 5, and cutout NB to accommodate centre ridge support Q, and showing tie down straps NC that are secured by buckles F1, Q shows one form of ridge support that engages in support holes A1 and supports cover/closure N, R shows one form of space divider where hooks at each end engage at random locations on mesh end infills 1D,

In DWG 1, O shows an end view of an erect pallet frame assembly, P shows a front view of a pallet frame assembly.

Dwgs 4 & 5 show illustrations of how with the deletion of metal pallet deck members and strap feet members the remaining fold down side/end frames can be adapted and fixed to a new or existing timber pallet to perform the same or similar tasks and functions as the all steel option described above and an illustration of the slotted and sliding hinge arrangement that is required on both steel and timber pallet bases in a format where one fold down side/end frame overlaps the opposite end/side frame.

In these drawings of the timber pallet option of the technology, where appropriate the same numbers are used to identify the same or similar components as the all steel option, where in DWG 5, 1 illustrates the fold down side/end frame with attached 1A metal channel infills in lieu of metal mesh, 2 illustrates the stub angle corner posts fixed to end angle members 3, 2A are nesting cleats fixed to 2 designed to support an above stacked pallet when one side/end frame overlaps the opposite side end frame when in the collapsed position, 2B is the slotted hinge hole in 2 which allows one fold down side/end frame to overlap the opposite side end frame when in the collapsed position, 2C is the locking hole at the top of 2 designed to engage locking pin 2D when in the open and erect position. 2D is the locking pin attached to 1 designed to engage locking slot 2C and used to hold the fold down side/end in an erect and open position, 3 illustrates end angle section which provides a fixing point for bag fixing pins 9, stub posts 2 and slotted fixing cleats 7, 5 is the bag support and drop bar designed to engage the sleeves in the top front and back of the bags, 6 are the fixing hinge pin/bolt connections attaching the fold down side end frames to the fixed base, 7 illustrates a slotted fixing cleat attached to side/end angle member 3, 7B shows a bolt and nut fixing that penetrates 7 and engages clamp plate 7A to provide a mechanical clamping action on the pallet decking, 7A is clamp fixing plate described above, 9 are bag fixing pins designed to engage sleeves 10A in bottom front and back of the bag component.

In DWG 5, shows an end view of timber pallet and attached fold down side/end frame in the erect position with out a bag attached, B shows a front view of a timber pallet with a pair of fold down side/end frames attached with the drop bar connecting each side without the bag component, C shows collapsed view of same where in a format where one fold down side/end frame overlaps the opposite side when in the collapsed position, D shows a plan view of the lower fixed portions of the side/end frames attached to a timber pallet.

In DWG 4 F shows a end view of timber pallet and fold down side/end frame assembly in the erect position with a bag attached, G shows a front view of same, H shows an end view of a collapsed frame assembly fixed to a timber pallet, I shows a front view of I with a bag attached, L shows a side view of stacked and interlocked erected timber pallet and fold down side/end frame assemblies with bags attached, M shows a front of L, N shows a front view of collapsed, stacked and interlocked timber pallet and fold down side/end frame assemblies with bags attached. 

1.-56. (canceled)
 57. A collapsible pallet frame and bag container supported on four U-shape strap metal feet where the outer legs of the U shapes are substantially vertical and positioned to mechanically engage purpose made enclosed corners of the pallet frame assembly such as to permit nestable stacking in both the collapsed and erected formats.
 58. A collapsible pallet frame and bag container as described in claim 57, where the internal corners of the stub angle posts are used to provide the vertical mechanical engagement of the U-shape strap metal feet of another pallet when stacked above when the lower pallet is in the collapsed format.
 59. A collapsible pallet frame and bag container as described in claim 57, where the hinge pin connections are vertically positioned below the top of the stub posts so that the opposite leg of the angle above the hinge pin location functions as a mechanical stop to the upward hinging end frame.
 60. A collapsible pallet frame and bag container as described in claim 57, where the vertical members (when erected) of the hinge down end frames will extend a small distance above the adjoined horizontal angle member where the horizontal member will overlap the inside flange of the vertical member and extend as far as practical into the corner of the adjoined vertical angle member such as to provide a enclosed three way corner where the three way corners will be used to mechanically capture the U-shape strap metal feet or corners of another pallet when stacked above.
 61. A collapsible pallet frame and bag container as described in claim 57, where the outer ends of the top members (when erected) of the hinge down end frames will have an inward facing horizontal flat male tab attached where the said flat male tab will include a hole and where the tab will be designed to fit inside a horizontally disposed and detachable square metal tube that forms the top (drop) bar and bag container support (described later) and which said drop bars incorporates internal male pins positioned to engage the holes in the said flat male tabs and so when attached will co-join the top front and back areas of the hinge down end frames.
 62. A collapsible pallet frame and bag container as described in claim 57 where a pair of generally square hollow tubes with vertical pins located internally near each end will be used to slide through longitudinal sleeves in the top front and back of the bag container and engage flat male tabs attached to the hinge down end frames and so join the hinge down end frames and hold and suspend the bag container in an open and erect position.
 63. A collapsible pallet frame and bag container as described in claim 57, where a narrower format requires one hinge down end frame to fold down on top of another hinge down end frame the stub posts at each end of the pallet base may incorporate a slotted hinge aperture in lieu of a circular hinge aperture wherein the said slotted aperture will allow one hinge down end frame to fold down on top and overlap the opposing hinge down end frame.
 64. A collapsible pallet frame and bag container as described in claim 57, where the bottom corners of the bag container will be held flat and symmetrical by short horizontal pins fixed at one end to the inner vertical face of the end angle sections co-joining the deck sections of the pallet base where the said pins will be designed to engage corresponding sleeves at the bottom front and back of the bag container.
 65. A collapsible pallet frame and bag container as described in claim 57, where metal battens in the form of tubes may be used to slide into continuous horizontal sleeves in the bag container where the said battens will provide stiffening and rigidity to the bag container and where said battens may or may not attach to the hinge down end frames or the pallet base.
 66. A collapsible pallet frame and bag container as described in claim 57, where the bag container component will consist of five sides in the form of an open top box and where the said bag container will be designed to fit closely inside the erected frame.
 67. A collapsible pallet frame and bag container as described in claim 57, where the bag container component will have horizontal sleeves at the top front and back where the said sleeves will be designed to accommodate metal support bars also described as drop bars where when erected the said drop bars will attach to the hinge down end frames and where the said drop bars will hold the bag open in a square and symmetrical position.
 68. A collapsible pallet frame and bag container as described in claim 57, where the bag container component will have horizontal sleeves at the bottom front and back where the said sleeves will be designed to fit over horizontal pin connectors and where the said connecting pins will hold the base of the bag spread open and substantially flat against the top surface of the pallet deck or where the said sleeves may be used to accommodate other slide in full length metal battens which may or may not attach to the pallet base.
 69. A collapsible pallet frame and bag container as described in claim 57, where the bag container will have other horizontal sleeves located elsewhere on the bag where the said sleeves will be designed to accommodate slide in full length metal battens where the said battens may or may not attach to the hinge down end frames and where the said battens will provide added stiffness and rigidity to the bag container.
 70. A collapsible pallet frame and bag container as described in claim 57, where the bag container may provide for personal access with a front cutaway area that creates a lower horizontal level of access and where when the said cutaway area and lowered level of access is not required, the said cutaway area will be closed and concealed behind a full width self apron front incorporating the top drop bar sleeve, fixed below the cutaway area and where the said drop bar will attach to the hinge down end frames in the normal way as previously described.
 71. A collapsible pallet frame and bag container as described in claim 57, where the bag container with the various drop bars and battens attached will upon detaching the top drop bars from the hinge down end frames be capable of folding down flat on top of the pallet deck in a manner that will permit the hinge down end frames to fold down on top of the bag and batten assembly in a substantially horizontal format.
 72. A collapsible pallet frame and bag container as described in claim 57, where the metal deck sections may be deleted and the remaining end angle, stub posts and hinge down end frame may be attached to a timber pallet base with cleats or brackets wherein the invention with the said timber pallet base will perform all the same or similar tasks and functions as described herein before.
 73. A collapsible pallet frame and bag container as described in claim 57, where in the erected format battens used to support the front and back of the bag may mechanically engage behind the vertical angle legs of the hinge down end frames where so disposed the said battens will confine and restrict the tendency of the loaded bag to bulge or belly. 